Radially expanding post extender

ABSTRACT

A post coupler expands laterally. The post coupler includes a first member that is hollow and has a first slanted face. A second member is also hollow and has a second slanted face that is abutted with the first slanted face. A rod extends through the first and second members; the rod has a head that is disposed at a head end and threads disposed at a thread end. A nut is engaged with the threads, and rotating the nut causes the first member to extend in a first lateral direction and causes the second cylindrical member to extend in a second lateral direction opposite the first radial direction.

BACKGROUND OF THE INVENTION Technical Field of the Invention

The present invention relates generally to barriers (such as railings orfences) and in particular to a device that facilitates construction of abarrier.

Description of Related Art

A homeowner who would like to increase the height of an existing fencethat includes steel poles generally has two options. The homeowner canremove his original height fence posts, usually six feet tall, from theground. This typically involves digging into the ground to remove afence post that has been anchored in concrete. Alternatively, thehomeowner may use a fence post extender sleeve. The extender sleeveincludes a pair of flared portions. One of the portion fits over anouter diameter of the existing fence post, and the second flared portionreceives an outer diameter of an extension post. The sleeve may besecure to the post using a bracket that radially compresses the flaredportions around the inserted post. The increased diameter of a portionof the fence post created by the sleeve may be undesirable because itmay be unsightly and may hinder or prevent a post bracket from beingslid in correct position up and down the post due to the increased outerdiameter of the post sleeve.

SUMMARY

In an embodiment, a post coupler is laterally expandable. The postcoupler includes a first member that is hollow and has a first slantedface. A second member is also hollow and has a second slanted face thatis abutted with the first slanted face. A rod extends through the firstand second members; the rod has a head that is disposed at a head endand threads disposed at a thread end. A nut is engaged with the threads,and rotating the nut causes the first member to extend in a firstlateral direction and causes the second cylindrical member to extend ina second lateral direction opposite the first radial direction. In anembodiment, the post coupler is cylindrical and radially expandable inopposite radial directions.

According to one embodiment, the radially expanding post coupler isreceived in an open end of an existing fence post. The post coupler isradially expanded such that it impinges on an inner surface of the fencepost, and a post extension is threaded onto the threaded rod of the postcoupler.

According to an alternate embodiment, the radially expanding postcoupler is post anchor. The post coupler is received in a boreholedrilled in a wooden fence post. The post coupler is radially expanded tosecure it within the borehole. The threaded rod is then received in athreaded bore of a base member to secure the post to the base member andanchor the post.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the method and apparatus of the presentinvention may be acquired by reference to the following DetailedDescription when taken in conjunction with the accompanying Drawingswherein:

FIG. 1 is a perspective view with portions broken away of a fence panelincluding a radially expanding post extender according to the teachingsof the present disclosure;

FIG. 2 is an exploded, perspective view of a the radially expanding postextender and post extension shown in FIG. 1;

FIG. 3 is an elevation view with portions in cross-section of theradially expanding post extender engaged with a post extension accordingto the teachings of the present disclosure;

FIG. 4 is an isometric view of an alternate embodiment of a postextension system employing dual radially expandable couplers;

FIG. 5 is an isometric view of an alternate embodiment of an expandablecoupler having a non-circular cross section;

FIG. 6 is an exploded, perspective view of a radially expanding postanchor according to the teachings of the present disclosure; and

FIG. 7 is an elevation view of the radially expanding post anchor ofFIG. 4 shown engaged in a borehole formed in a center of a wooden post.

DETAILED DESCRIPTION

Reference is now made to FIG. 1 which illustrates a perspective view ofa portion of a fence panel 10. The fence panel 10 includes radiallyexpanding post extenders 12, also referred to herein as radiallyexpandable post couplers, according to the teachings of the presentdisclosure. The radially expanding post extenders 12 allow the height offence posts and a fence to be easily increased while keeping theradially expanding post extenders 12 hidden, which results in a morepleasing appearance of an extended fence panel 10.

The original fence may have been installed by a homeowner to have aheight of approximately six feet. The homeowner may have a desire or aneed for a taller fence, for example eight or nine feet, and theoriginal steel cylindrical fence posts are still usable but just nottall enough. The homeowner can use the radially expanding post extenders12 to increase the height of each fence post to increase the height ofhis fence up to three additional feet, which may be suitable to enclosea pool or may be desirable to increase the privacy of a backyard.

The fence panel 10 includes a pair of fence posts 14 (only one shown)that are disposed at each end of the fence panel 10. The fence posts 14extend vertically. According to certain embodiments, the fence posts 14are coupled to a post anchor (not shown). The post anchor may include aplurality of fins that taper to a point as shown and described in U.S.Pat. No. 7,730,675, entitled “Post Anchor with Post HoldingImpressions,” by Ian Hill, which is incorporated herein by reference.

The fence posts 14 support horizontal support members 16 that extendfrom one fence post 14 to the other fence post 14 disposed at theopposite side of the fence panel 10. The horizontal support members 16are disposed spaced apart vertically along the fence posts 14. Accordingto certain embodiment, brackets 18 secure the horizontal support members16 to the fence posts 14. An example of a bracket 18 is shown anddescribe in U.S. Pat. No. 9,115,506, entitled “Wood to Pipe Bracket anda Connection Utilizing Such a Bracket,” which is hereby incorporated byreference.

Because the radially expandable post coupler 12 is primarily disposedinside the hollow post and an outer diameter of an upper washer 26 isgenerally flush with the outer diameter of the fence post 14, thebracket 18 may be easily received over the top end of the fence post,and then slid to the appropriate position on the fence post 14 includingover the junction of a post extension 24 to an existing fence post 22and secured in place. When conventional post extension sleeves are used,the bracket 18 may not slide smoothly over an increased outer diameterportion of the coupler sleeve.

The horizontal support members 16 support a plurality of slats 20. Eachslat 20 runs vertically, and collectively the slats create the barrierof the fence panel 10. The horizontal support members 16 and the slats20 are generally formed of wood, but in certain embodiments may beformed of metal such as steel or aluminum. The slats 20 are fastened tothe horizontal support members 16 using any suitable fasteners, such asnails, screws, bolts, and the like.

The radially expanding post extender 12 is disposed in a top portion ofeach of the original height fence posts 22, as described in more detailbelow. The post extender 12 allows a post extension 24 to be coupled tothe original height fence post 22, which allows the height of the fencepanel 10 to be increased. The extended height fence post 14 supportsadditional horizontal support members 16, which support longer slats 20.The radially expanding post extender 12 is a considerable improvementover conventional increased height fences because the original heightfence post does not need to be removed and replaced with a higher fencepost in order to increase an overall height of a fence. As stated above,the anchor of the original height fence post may have been secured inthe ground with cement or concrete, so avoiding removal of the anchorfrom the ground significantly simplifies and reduces the effort requiredto increase the height of the fence. Also, the radially expandable postextender 12 is concealed within the hollow cavity of the fence post 14,and therefore blends seamlessly into the fence post 14.

FIG. 2 is an exploded, perspective view of the radially expanding postextender 12 and the post extension 24 shown in FIG. 1. As shown in FIG.1, the radially expanding post extender 12 is inserted into an existinghollow post 22. The upper washer 26 has an outer diameter equal to orgreater than a diameter of the existing fence post 22. The upper washer26 contacts the upper end face 27 of the existing fence post 22 (seeFIG. 3) and ensures that the radially expanding post extender 12 remainsdisposed at an upper end of the existing fence post 22 upon initialinsertion. A rod 28 extends through the radially expanding post extender12. The rod 28 includes threads 30 disposed at least at a threaded endof the rod 28. A head 32 is disposed at a head end of the rod 28opposite the threaded end.

Three hollow cylindrical members are disposed to surround the rod 28 andare allowed to float axially and radially on the rod 28. An uppercylindrical member 34 is hollow and is disposed proximate the upperwasher 26. The upper cylindrical member 34 includes an upper abutmentface 36 and a slanted abutment face 38. The slanted abutment face 38 maybe slanted at an angle in a range of 20°-70°, for example 45°. Anintermediate cylindrical member 40 is also hollow and disposed axiallybelow the upper cylindrical member 34. An upper slanted abutment face 42abuts the lower slanted abutment face 38 of the upper cylindrical member34. A lower slanted abutment face 44 abuts a lower cylindrical member46. The lower cylindrical member 46 is disposed axially below theintermediate cylindrical member 40. Similar to the upper cylindricalmember 34, the lower cylindrical member 46 includes a lower abutmentface 48 and a slanted abutment face 50 that abuts the lower slantedabutment face 44 of the intermediate cylindrical member 40. The lowerabutment face 48 contacts a lower washer 52. The lower washer 52includes a through hole 54 through which the rod 28 extends. The throughhole 54 is sized to be smaller than the head 32. According to certainembodiments, the through hole 54 has a diameter that is less than thediameter of the head 32. According to an alternate embodiment, the rod28 may be a carriage bolt. The through hole 54 in the lower washer 52may be square to correspond to a shape of a neck portion of the rod 28disposed at the junction of the head 32 with the body of the rod 28.Engagement of the square rod neck with the square-shaped through hole 54prevents the rod 28 from spinning during assembly.

FIG. 3 is a detailed view of the cross-section shown in FIG. 1 with thebracket 18 removed for clarity. After inserting the radially expandingpost extender 12 into the existing fence post 22, a nut 56 is rotated onthe threads 30 of the rod 28. Rotating the nut 56 draws the head 32 ofthe rod 28 towards the nut 56. The head 32 directs the lower washer 52upward toward the nut 56, and the lower washer 52 directs the lowercylindrical member 46 upward toward the nut 56. The upward movement ofthe lower cylindrical member 46 acts to cause the intermediatecylindrical member 40 to slide radially outward on its upper and lowerslanted faces 42, 44. In turn, the upper and lower cylindrical members34, 46 slide radially outward along their respective slanted abutmentfaces 38, 50. The slanted abutment faces 42, 44 cause the intermediatecylindrical member 40 to extend in a first direction radially outwardand cause the upper and lower cylindrical members 34, 46 to extend in asecond direction opposite the first direction radially outward. Theradial expansion of the intermediate cylindrical member 40 and the upperand lower cylindrical members 34, 46 impinge on an inner surface 58 ofthe existing fence post 22. This impingement increases the frictionalforce between the cylindrical members 34, 40, 46 and the inner surface58 of the existing fence post 22. Thus, the radially expandable coupler12 is tightly engaged with the exiting fence post 22 because the shearforce required to displace the radially expandable coupler 12 isincreased as the nut 56 is turned and the radially expandable coupler 12is radially expanded.

A portion of the threaded rod 28 extends beyond the nut 56. This portionis received by a threaded hole 60 formed in an insert 62 that is coupledto the extension post 24. According to certain embodiments, the insert62 may be welded or otherwise secured within the opening of the postextension 24. The post extension 24 is rotated to engage the threadedhole 60 with the threads 30 of the rod 28. Because the radiallyexpandable coupler 12 is tightly secured against displacement within theexisting post 22, as described above, the post extension 24 can berotated against the stationary threaded rod 28 to thereby secure thepost extension 24 to the radially expandable coupler 12. The upperwasher 26 is disposed axially between the existing fence post 22 and thepost extension 24. The nut 56 is concealed in a gap 64 formed betweenthe insert 62 and the upper washer 26.

Each of the upper and lower washers 26, 52 and the upper, lower, andintermediate cylindrical members 34, 40, 46 are formed of any suitablematerial, such as galvanized steel of any suitable gauge, such asthirteen or sixteen gauge. The upper washer 26 may have an outerdiameter that allows it to be flush with the outer diameter of theexisting fence post 22 and the post extension 24. According to certainembodiments, standard steel fence posts have an outer diameter of 2.375inches. Therefore, the outer diameter of the upper washer 26 may beapproximately 2.375 inches. However, any suitable diameter iscontemplated by this disclosure. An outer diameter of the lower washer52, the upper cylindrical member 34, the lower cylindrical member 46,and the intermediate cylindrical member 40 is less than the innerdiameter of the existing fence post 22. According to certainembodiments, the outer diameter of the lower washer 52, the uppercylindrical member 34, the lower cylindrical member 46, and theintermediate cylindrical member 40 is approximately 1.875 inches;however any suitable outer diameter is contemplated by this disclosure.

The post extension 24 is about 36 inches in length. An installer may cutthis length to any desired shorter length, such as two feet to extend asix foot fence to an eight foot fence.

According to an alternate embodiment, the radially expandable postextender 12 may be used to couple a post with a larger or smallerdiameter than the diameter of the existing post. For example, a propertyowner may want to replace a chain link fence with a privacy fence. Theproperty owner may cut the fence posts of the chain link fence near theground. A radially expandable post coupler 12 is inserted into the fencepost portion remaining after the cut. The radially expandable postcoupler 12 is sized to be received in a chain link fence post, whichtypically has an outer diameter of 1.875 inches and may be formed ofsixteen gauge galvanized steel. The post coupler 12 is expanded tosecure it into the interior of the fence post. And then a largerdiameter post extension, for example a post extension with an outerdiameter of 2.375 inches may be threaded to the threaded rod 28 of theradially expanding post coupler 12. This disclosure contemplates sizingthe components to extend tubes of all sizes and diameters, regardlesswhether the joined tubes have the same diameter.

According to a further alternate embodiment, the radially expanding postcoupler 12 may be received, expanded, and secured in a hole that hasbeen drilled in a solid foundation, such as a concrete or cementfoundation. In this manner, a post extension may be made without anexisting post. Such employment of the radially expanding post couplermay be particularly useful in erection of hand railings, sign posts, andthe like.

Reference is made to FIG. 4, which is an isometric view of an alternateembodiment of a post/tube extension system 120 according to theteachings of the present disclosure. The system 120 includes a pair ofradially expandable couplers 12 coupled together by a coupler 122.

The coupler 122 is generally cylindrical and includes a body 124 and apair of rims 126 disposed opposite the body 124 of each other. Thecoupler 122 includes a first threaded bore 128 a and a second threadedbore 128 b that is coaxial with the first threaded bore 128 a. One ofthe radially expandable couplers 12 may be inserted into a hollowcylindrical member, such as a fence post. The radially expandablecoupler 12 is expanded to secure it within the hollow cylindricalmember, as described above. A second radially expandable coupler 12 isinserted into a second hollow cylindrical member, such as a fence postextension, and it is radially expanded to secure it to the interior ofthe second hollow cylindrical member. The threaded portion of thethreaded rods 28 of each radially expandable coupler 12 is received inthreaded engagement with a respective threaded bore 128 a, 128 b of thecoupler 122. In this manner, the two hollow cylindrical members can bejoined together with the coupler 122 disposed between the hollowcylindrical members. Joining hollow cylindrical members according to thesystem 120 allows any hollow cylindrical members to be joined, not justthose where an insert has been welded or otherwise secured to anextension post. Thus, the installer may couple together a variety ofsizes of hollow cylindrical members.

FIG. 5 illustrates an alternative embodiment of an expandable coupler140 according to the teachings of the present disclosure. The expandablecoupler 140 is non-circular in cross section. For example, theexpandable coupler 140 is rectangular or square in cross section. Theexpandable coupler 140 may be particularly useful in extending a lengthof a fence post that is hollow and has a rectangular or square crosssection. The expandable coupler 140 functions similar to the radiallyexpandable coupler 12. The installer inserts the expandable coupler 140into an end of a hollow member with a square or rectangular crosssection. The nut 142 is rotated on the threaded rod 144 to draw the rodhead 146 toward the nut 142. The slanted abutment faces of the lowerhollow member 148 and the upper hollow member 150 slide on respectiveslanted abutment faces of an intermediate hollow member 152. The upperand lower hollow members 148, 150 are displaced in a first lateraldirection, and the intermediate hollow member is displaced in a secondlateral direction opposite the first direction. This displacementsecures the expandable coupler 140 within the hollow member. The exposedportion of the threaded rod 144 is received in a threaded bore of aninsert, as described above with respect to FIG. 2, or in an alternateembodiment, the exposed portion of the threaded rod 144 is received in athreaded bore of a coupler, as described above with respect to FIG. 4.

FIG. 6 is an exploded view of a radially expanding post anchor 70. FIG.7 illustrates the radially expanding post anchor 70 disposed inside aborehole 74 in a wooden post 72. The post 72 may have a square-shapedcross section, but other cross-section shapes are possible. As shown inFIG. 7, the borehole 74 is drilled into a bottom surface 76 of the post72, and the radially expandable post anchor 70 is inserted into the hole74. The borehole 74 is drilled or otherwise formed at a center of thebottom surface 76. The post 72 is secured to a base member 106 such thatthe outer surface 75 of the post is generally aligned with the perimeterof the base member 106.

Similar to the radially expandable post extender 12 described above, athreaded rod 78 extends through an upper cylindrical member 80, anintermediate cylindrical member 82 and a lower cylindrical member 84,where each is hollow and surrounds the threaded rod 78 such that theyare allowed to float radially. A lower washer 86 is disposed axiallybetween a nut and 88 and a square abutment face 89 of the lowercylindrical member 84. An upper washer 90 is disposed axially between ahead 92 and a square abutment face 91 of the upper cylindrical member80. According to some embodiments, the upper washer 90 may be omittedand the head 92 may act directly on the upper cylindrical member 80.

The radially expanding post anchor 70 is received within the borehole74. According to certain embodiments, the head 92 of the rod 78 contactsa floor surface 93 of the borehole 74. Tightening the nut 88 displacesthe lower washer 86 and the lower cylindrical member 84 toward the head92 of the rod 78. The movement of the lower cylindrical member 84 actsto cause the intermediate cylindrical member 82 to slide radiallyoutward on its upper and lower slanted faces 94, 96. In turn, the upperand lower cylindrical members 80, 84 slide radially outward along theirrespective slanted abutment faces 98, 100. The intermediate cylindricalmember 82 extends in a first direction radially outward, and the upperand lower cylindrical members 80, 84 extend radially outward in a seconddirection opposite the first direction. The radial expansion of theintermediate cylindrical member 82 and the upper and lower cylindricalmembers 80, 84 impinge on an inner surface 102 of the borehole 74 of thepost 72. A protrusion 104 extends from each of the upper, lower, andintermediate cylindrical members 80, 82, 84. The protrusion 104 isconfigured to dig into the wood as the post anchor 70 expands radially.The engagement of the protrusion 104 and the wood secures the postanchor 70 against displacement. Thus, the radially expandable postanchor 70 is tightly engaged with the post 72 because the shear forcerequired to displace the radially expandable post anchor 70 is increasedas the nut 88 is turned and the radially expandable post anchor 70 isradially expanded.

According to an alternate embodiment, the intermediate cylindricalmember 82 may be omitted, and the upper cylindrical member 80 extendsradially in one direction and the lower cylindrical member 84 extends inthe opposite radial direction.

A base member 106 is secured using a plurality of fasteners (not shown)that extend through each of a plurality of countersunk through holes 108in the base member 106. For example, the base member 106 may have fourthrough holes 108, which each receive a screw through the through hole106 and into a deck surface. The deck surface may be metal, wood, orconcrete.

The base member 106 includes a threaded bore formed in a protrusion 110extending from a center of the base member 106. The threaded bore isconfigured to receive the threads of the threaded rod 78 after the postanchor 70 has been tightly secured within the borehole 74, as describedabove. Rotation of the fence post 72 engages the threads of the rod 78with the threaded bore of the protrusion 110 of the base member 106. Thefence post 72 is rotated until the bottom surface 76 of the fence post72 abuts an upper surface 112 of the base member 106. The post anchor 70is secured against displacement and slippage by the protrusions 104 thatare wedged in the depressions that are formed in the wood of the post72.

Although preferred embodiments of the method and apparatus of thepresent invention have been illustrated in the accompanying Drawings anddescribed in the foregoing Detailed Description, it will be understoodthat the invention is not limited to the embodiments disclosed, but iscapable of numerous rearrangements, modifications and substitutionswithout departing from the spirit of the invention as set forth anddefined by the following claims.

1. A post coupler, comprising: a first member being hollow and having afirst slanted face; a second member being hollow and having a secondslanted face abutted with the first slanted face; a rod extendingthrough the first and second members, the rod having a head disposed ata head end and threads disposed at a thread end; and a nut engaged withthe threads, wherein rotating the nut causes the first member to extendin a first lateral direction and causes the second member to extend in asecond lateral direction opposite the first lateral direction.
 2. Thepost coupler of claim 1 further comprising a first washer disposedaxially between the nut and the first member and a second washerdisposed axially between the head and the second member.
 3. The postcoupler of claim 1 further comprising a washer disposed proximate thehead of the rod and a neck disposed at the head end of the rod having asquare-shaped cross section corresponding to a square shaped throughhole in the washer.
 4. The post coupler of claim 1 wherein each of thefirst and second members include a protrusion extending from externalsurfaces of the first and second members.
 5. The post coupler of claim 1further comprising a base member defining a threaded bore disposedproximate a center of the base member, the threaded bore configured toreceive the threads extending beyond the nut.
 6. The post coupler ofclaim 1 further comprising a post extension having an insert disposed atan end of the post extension, the insert defining a threaded boreconfigured to receive the threads extending beyond the nut.
 7. The postcoupler of claim 1 wherein the first and second members have arectangular or square cross section.
 8. The post coupler of claim 1wherein the first and second members are cylindrical and the first andsecond lateral directions are radial directions.
 9. A post coupler,comprising: a first cylindrical member having a first slanted abutmentface; a second cylindrical member having a second slanted abutment face;a third cylindrical member disposed axially between the first and secondcylindrical members and having a third slanted abutment face configuredto abut with the first slanted abutment face and a fourth slantedabutment face configured to abut with the second slanted abutment face;a rod extending through the first, second, and third cylindrical membersand having a head disposed at a head end and threads disposed at athread end; and a nut engaged with the threads, wherein tightening thenut causes the first and second cylindrical members to extend radiallyin a first direction and causes the third cylindrical member to extendradially in a second direction opposite the first direction.
 10. Thepost coupler of claim 9 wherein each of the first, second, and thirdcylindrical members are hollow.
 11. The post coupler of claim 9 furthercomprising a first washer disposed at the thread end of the rod and asecond washer disposed at the head end of the rod.
 12. The post couplerof claim 11 wherein a neck portion of the rod disposed at the head endof the rod has a square-shaped cross-section and the second washer has acorresponding square-shaped through hole.
 13. The post coupler of claim11 wherein the first washer is disposed axially between the nut and thefirst cylindrical member and the second washer is disposed axiallybetween the head and the second cylindrical member.
 14. The post couplerof claim 9 wherein a portion of the rod and the threads extend beyondthe nut and are configured to be received by a corresponding threadedhole.
 15. The post coupler of claim 9 further comprising a base memberdefining a threaded bore disposed proximate a center of the base member,the threaded bore configured to receive the threads extending beyond thenut.
 16. The post coupler of claim 9 further comprising a post extensionhaving an insert disposed at an end of the post extension, the insertdefining a threaded bore configured to receive the threads extendingbeyond the nut.
 17. The post coupler of claim 9 further comprising acoupler having a first threaded bore and a second threaded bore coaxialwith the first threaded bore, the first and second threaded bores eachconfigured to receive the threads extending beyond the nut.
 18. A systemfor extending a post, comprising: a first post member; an insertdisposed in one end of the first post member, the insert defining athreaded hole; and a post coupler configured to be inserted into an endof a second post member, the post coupler having a threaded rod and anut disposed thereon, and wherein tightening the nut radially expandsthe post coupler and the threaded rod is configured to be received bythe threaded hole of the insert.
 19. The system of claim 18 wherein theinsert is welded in the one end of the first post member.
 20. The systemof claim 18 wherein the post coupler further comprises a washer sized tocontact an end surface of the second post member when the post coupleris inserted into the end of the second post member.
 21. The system ofclaim 20 wherein the post coupler further comprises a hollow cylindricalmember and an end surface of the hollow cylindrical member contacts thewasher.
 22. The system of claim 21 wherein the nut is disposed withinthe first post member.